U.S. patent application number 10/639721 was filed with the patent office on 2005-02-17 for automated instrument sorting system.
This patent application is currently assigned to STERIS Inc.. Invention is credited to Delisle, Andre, Gagnon, Alain.
Application Number | 20050038556 10/639721 |
Document ID | / |
Family ID | 34135933 |
Filed Date | 2005-02-17 |
United States Patent
Application |
20050038556 |
Kind Code |
A1 |
Gagnon, Alain ; et
al. |
February 17, 2005 |
Automated instrument sorting system
Abstract
An automated system for sorting articles, such as medical
instruments, by a selected sort criteria. In one embodiment of the
present invention, medical instruments are sorted in accordance
with an instrument set list for assembling a medical instrument
set. The present invention minimizes or eliminates the amount of
manual labor needed to sort instruments, minimizes human contact
with the instruments, speeds the sorting process, and reduces
sorting errors.
Inventors: |
Gagnon, Alain; (Quebec,
CA) ; Delisle, Andre; (St. Nicolas, CA) |
Correspondence
Address: |
KUSNER & JAFFE
HIGHLAND PLACE SUITE 310
6151 WILSON MILLS ROAD
HIGHLAND HEIGHTS
OH
44143
US
|
Assignee: |
STERIS Inc.
|
Family ID: |
34135933 |
Appl. No.: |
10/639721 |
Filed: |
August 12, 2003 |
Current U.S.
Class: |
700/226 |
Current CPC
Class: |
A61B 90/94 20160201;
A61B 2017/00526 20130101; A61B 90/90 20160201; G16H 40/20
20180101 |
Class at
Publication: |
700/226 |
International
Class: |
G06F 007/00 |
Claims
1. A method for processing medical instruments undergoing at least
one biocontamination reduction process, comprising the steps of:
locating a plurality of medical instruments onto a conveyance means
having a plurality of destination sites; conveying each of the
medical instruments past imaging means; reading a machine-readable
code located on each medical instrument to select from a plurality
of destination sites a destination site associated with the medical
instrument; and conveying each medical instrument to the
destination site associated therewith, wherein each of said
plurality of destination sites collects a set of medical
instruments according to a sort criteria.
2. A method according to claim 1, wherein said sort criteria is
selected from the group consisting of: medical instrument sets,
like instruments, and like biocontamination reduction
processes.
3. A method according to claim 1, wherein said method further
comprises: accessing a database with the machine-readable code to
obtain data indicative of a destination site corresponding to the
sort criteria.
4. A method according to claim 3, wherein said database associates
machine-readable codes with at least one of: destination site,
instrument name, instrument type, medical instrument set,
in-service date, maintenance due date, last sort date,
biocontamination reduction process, serial number, storage
location, and owner name.
5. A method according to claim 1, wherein said plurality of medical
instruments are subject to a washing/disinfecting operation prior
to locating the plurality of medical instruments onto the
conveyance means.
6. A method according to claim 1, wherein the method further
comprises: transporting each set of medical instruments collected
at each of the plurality of destination sites to a sterilizing
apparatus; and sterilizing each set of medical instruments.
7. A method according to claim 6, wherein said method further
comprises: storing each set of sterilized medical instruments in a
storage facility.
8. A method according to claim 1, wherein each of said plurality of
destination sites collects a set of like medical instruments, that
are assembled into medical instrument sets comprised of medical
instruments from at least two of said plurality of destination
sites.
9. A method according to claim 1, wherein said machine-readable
code is selected from the group consisting of: Data Matrix and bar
code.
10. A method according to claim 1, wherein said method further
comprises identifying visibly damaged medical instruments.
11. A system for automated sorting of a plurality of medical
instruments, comprising: an imaging system for reading a
machine-readable code located on each medical instrument; a
tracking system using the machine-readable code to select a
respective destination site for each medical instrument from a
plurality of destination sites and transmitting destination site
data to the sorting apparatus that identifies the respective
destination site associated with each medical instrument; and a
sorting apparatus including: conveyance means for conveying each of
the medical instruments to the respective destination site selected
from the plurality of destination sites to collect a set of medical
instruments in accordance with a sort criteria, said conveyance
means having a plurality of destination sites.
12. A system according to claim 11, wherein said sort criteria is
selected from the group consisting of: medical instrument sets,
like instruments, and like biocontamination reduction
processes.
13. A system according to claim 11, wherein said sorting apparatus
further comprises control means for controlling operation of the
conveyance means
14. A system according to claim 11, wherein said tracking system
includes a database for associating machine-readable codes with at
least one of: destination site, instrument name, instrument type,
medical instrument set, in-service date, maintenance due date, last
sort date, biocontamination reduction process, serial number,
storage location, and owner name.
15. A system according to claim 11, wherein said system further
comprises a robotic arm for transferring the medical instruments
onto said conveyance means.
16. A system according to claim 11, wherein said system further
comprises a robotic arm for unloading medical instruments from the
destination site.
17. A system according to claim 11, wherein said machine-readable
code is selected from the group consisting of: Data Matrix and bar
code.
18. A system according to claim 11, wherein said machine-readable
code is permanently applied onto each medical instrument.
19. A system according to claim 11, wherein said imaging system
identifies visibly damaged medical instruments.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to an automated
system for article sorting, and more particularly to a system for
automated sorting of medical instruments by a selected sort
criteria.
BACKGROUND OF THE INVENTION
[0002] Surgical instruments used in a medical procedure will have a
significant effect on the quality and success of that medical
procedure. Between each medical procedure, the instruments must
undergo one or more biocontamination reduction processes (e.g.,
washing, disinfection, sterilization, decontamination, and the
like), and be assembled into correct and complete instrument sets,
in advance of a medical procedure. Each instrument set is comprised
of a predetermined group of instruments appropriate for a type of
medical procedure. Exemplary medical instrument sets include major
basic surgery set, minor basic surgery set, infant laparotomy set,
gynecological surgery set, basic orthopedic surgery set, basic
podiatry set, etc. Each of these medical instrument sets includes
different numbers and types of medical instruments.
[0003] Instrument sets become disassembled and unsorted following a
medical procedure and/or during a biocontamination reduction
process. After a medical procedure, instruments are typically
deposited at a central collection site where they get mixed with
instruments used in other medical procedures. With respect to a
biocontamination reduction process, individual instruments may
require different procedures (e.g., hand wash versus machine wash),
or be loaded into different racks or containers associated with a
biocontamination reduction device.
[0004] In most organizations, instrument "technicians" or
"assemblers" are responsible for instrument care and handling. An
instrument assembler must identify different types of instruments,
assemble instrument sets according to a predetermined list of
instruments, and know how each instrument should be processed for
biocontamination reduction. Assembly of instrument sets is a
tedious and time consuming process.
[0005] In order to provide proper instrument care and handling, an
instrument assembler must be properly trained in basic instrument
identification, and biocontamination reduction procedures.
Instrument identification is made difficult by the fact that there
are numerous different instruments, and many of the instruments
look very similar. To facilitate identification, instruments may be
marked with identifiers that correspond with instrument set
component lists and instrument catalogs.
[0006] There is also a need for tracking the use and inventory of
surgical instrument sets. In this regard, surgical instruments may
become lost (e.g., misplaced or stolen), or need repair.
[0007] The present invention addressed these and other problems by
providing an automated system for sorting medical instruments into
sets according to a sort criteria.
SUMMARY OF THE INVENTION
[0008] In accordance with the present invention, there is provided
a method for processing medical instruments undergoing at least one
biocontamination reduction process, comprising the steps of: (a)
locating a plurality of medical instruments onto a conveyance
means; (b) conveying each of the medical instruments past imaging
means; (c) reading a machine-readable code located on each medical
instrument to determine a destination site associated with the
medical instrument; and (d) conveying each medical instrument to
the destination site associated therewith, wherein each destination
site collects a set of medical instruments according to a sort
criteria.
[0009] In accordance with another aspect of the present invention,
there is provided a system for automated sorting a plurality of
medical instruments, comprising: (a) a sorting apparatus including
conveyance means for conveying each of the medical instruments to a
destination site to collect a set of medical instruments in
accordance with a sort criteria; (b) an imaging system for reading
a machine-readable code located on each medical instrument; and (c)
a tracking system for determining a destination site using the
machine-readable code, and transmitting destination site data to
the sorting apparatus that identifies the destination site
associated with the medical instrument.
[0010] An advantage of the present invention is the provision of an
automated sorting system and method that minimizes human
involvement in the instrument sorting and set assembly
processes.
[0011] Another advantage of the present invention is the provision
of an automated sorting system and method that minimizes human
contact with medical instruments.
[0012] Another advantage of the present invention is the provision
of an automated sorting system and method that reduces the risk of
error in assembly of instrument sets.
[0013] Another advantage of the present invention is the provision
of an automated sorting system and method that reduces the risk of
losing instruments.
[0014] Still a further advantage of the present invention is the
provision of an automated sorting system and method that reduces
costs associated with instrument sorting.
[0015] Still a further advantage of the present invention is the
provision of an automated sorting system and method that provides
computerized instrument tracking.
[0016] Yet another advantage of the present invention is the
provision of an automated instrument sorting system and method that
sorts instruments in accordance with a user-selectable sort
criteria.
[0017] Yet another advantage of the present invention is the
provision of an automated instrument sorting system and method that
facilitates paperless data management.
[0018] These and other advantages will become apparent from the
following description of a preferred embodiment taken together with
the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention may take physical form in certain parts and
arrangement of parts, a preferred embodiment of which will be
described in detail in the specification and illustrated in the
accompanying drawings which form a part hereof, and wherein:
[0020] FIG. 1 is a schematic illustration of an automated sorting
system, according to a preferred embodiment of the present
invention;
[0021] FIG. 2 is a block diagram of the tracking system of the
automated sorting system of FIG. 1;
[0022] FIG. 3 is a flow diagram illustrating operation of the
automated sorting system;
[0023] FIG. 4 is a flow diagram illustrating transport logistics of
instruments, according to a preferred embodiment of the present
invention; and
[0024] FIG. 5 is a perspective view of a portion of an instrument
having a machine-readable code located thereon.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0025] Referring now to the drawings wherein the showings are for
the purposes of illustrating a preferred embodiment of the
invention only and not for purposes of limiting same, FIG. 1
schematically illustrates an automated sorting system 2, according
to a preferred embodiment of the present invention. Sorting system
2 is generally comprised of a tracking system 10, an imaging system
30, and a sorting apparatus 50.
[0026] According to a preferred embodiment of the present
invention, imaging system 30 includes a CCD (charge coupled device)
video camera (i.e., imager) for `reading` a machine-readable code
6, as will be described in further detail below. For example,
imaging system 30 may take the form of the AccuVision AV1220 Real
Time Imaging System from Accu-Sort.RTM. Systems. inc. of Telford,
Pa. The AccuVision AV1220 includes a fixed focus CCD camera.
Accu-Sort.RTM. APC100 Decoder decodes all standard linear bar codes
and two-dimensional symbols commonly used in high-speed material
handling applications. In the illustrated embodiment, a second
imaging system 35 is provided to `read` a machine readable code 6
located on a bin or tray 90.
[0027] Machine-readable code 6 may take the form of symbol codes,
including, but not limited to, a two-dimensional symbol code (such
as Data Matrix symbology), a linear bar code, and the like.
Preferably, a machine-readable code 6 is applied to each instrument
5 (FIG. 5) and to each tray 90 that is processed by automated
sorting system 2, to serve as an identification code (ID).
Machine-readable code 6 is applied to medical instruments 5 and
trays 90, by way of example, and not limitation, engraving, laser
etching, labels and the like. According to a preferred embodiment,
each medical instrument 5 and tray 90 receives a unique
identification code that identifies the specific instrument 5 and
tray 90.
[0028] Data Matrix symbology is preferred for machine-readable code
6. In this regard, Data Matrix symbology employs Reed-Solomon error
correction with data redundancy to provide fast and accurate code
reading. Data Matrix symbology is scalable between a 1-mil square
to a 14-inch square, and is therefore particularly well suited to
marking small articles, such as medical instruments.
[0029] According to a preferred embodiment, sorting apparatus 50
includes a first conveyer unit 52 and a second conveyer unit 62
(illustrated in phantom in FIG. 1). First conveyer unit 52 is
comprised of a plurality of transport members 54 that are driven by
an endless loop (not shown). In a preferred embodiment, transport
members 54 discharge articles from conveyer unit 52 in a direction
transverse to the travel direction of transport member 54. In this
regard, each transport member 54 may include conventionally-known
cross-belts or tilt mechanisms. Second conveyer unit 62 is
preferably a conventional conveyer apparatus having a plurality of
travel paths 64 that pass under first conveyer unit 52. A
controller 58 (FIG. 2) controls the operation of sorting apparatus
50. Sorting apparatus 50 may take the form of a compact sorting
system, such as the Crisplant Compact Sorter (CCS). As will be
described in further detail below, first conveyer unit 52 and
second conveyer unit 62 respectively transport instruments 5 and
trays 90 to destination sites identified by tracking system 10.
[0030] Referring now to FIG. 2, tracking system 10 preferably takes
the form of a personal computer (PC), and includes a control unit
12, an input unit 14, a display unit 16 and memory 20. Control unit
12 may be a microprocessor. Input unit 14 may take the form of a
keypad, a keyboard, a touchscreen, or the like. Display unit 16 may
take the form of a video monitor, a LCD (liquid crystal display), a
LED (light emitting diode) display device, or other display
apparatus. Memory 20 may include, but is not limited to, RAM
(random access memory), ROM (read only memory), hard disk drive,
floppy disk drive, optical disc (e.g., compact disc and digital
video disc), or other data storage device. Data is transmitted
between tracking system 10 and imaging system 30, sorting apparatus
50 and other systems 100 (e.g., accounting systems, supplier
computer systems, ordering systems, etc.), as will be explained in
further detail below.
[0031] Memory unit 20 provides storage for a database 22 that
stores information for assembling sets of instruments by one or
more sort criteria. By way of example, and not limitation, database
22 may store information for sorting instruments according to: (1)
medical instrument set lists, in order to sort instruments 5 into
pre-defined medical instrument sets (e.g., a major basic surgery
set); (2) instrument type, in order to sort instruments 5 into sets
of like instruments; and (3) biocontamination reduction processes,
in order to sort instruments 5 into sets of instruments that
undergo the same biocontamination reduction process.
[0032] In a preferred embodiment, the sort criteria is selectable
by a user through input unit 14. Database 22 may store tables of
data associating each machine-readable code 6 with data including,
but not limited to, destination site, instrument name, instrument
type, medical instrument set, in-service date, maintenance due
date, last sort date, biocontamination reduction process, serial
number, storage location, owner name, and tray type. Using the
information stored in database 22 tracking system 10 determines a
destination site for each instrument 5, in accordance with the
selected sort criteria. In the illustrated embodiment, sorted sets
of instruments are stored in trays 90. Accordingly, tracking system
10 may also determine a destination site for each tray 90.
[0033] It should be understood that tracking system 10 may provide
numerous functions in addition to those discussed above. In this
respect, tracking system 10 may also provide a system for
monitoring lost and stolen instruments, instrument inventories,
instrument maintenance and repair schedules, and the like. Tracking
system 10 may also provide report generating functions.
[0034] With reference to FIGS. 1, 3 and 4, operation of automated
sorting system 2 will now be described in connection with a sorting
operation, wherein instruments 5 are sorted into medical instrument
sets (e.g., major basic surgery set). It should be appreciated that
a preferred embodiment of the present invention is described with
reference to the sorting of medical instruments 5. However, it is
contemplated that the present invention also finds utility in
connection with the sorting of other types of articles.
[0035] Sterile medical instruments 5 are initially sorted into
medical instrument sets and are stored in trays 90 in a storage
facility (e.g., a storage room) (step 412). When a medical
instrument set is needed for a particular medical procedure, the
set of sorted instruments 5 is transported from storage facility
412 to a surgery room (step 414). Following the completion of a
medical procedure, the set of instruments 5, including "soiled"
(i.e., contaminated) and unsoiled instruments, is typically
disposed of at a central collection site, where the set of
instruments 5 becomes co-mingled with sets of instruments 5 used in
other medical procedures. Accordingly, medical instruments 5 become
unsorted.
[0036] In order to re-use instruments 5, they must undergo one or
more biocontamination reduction processes. Accordingly, the
unsorted instruments 5 are transported to a washer/disinfector
(step 416) to undergo a first biocontamination reduction process.
Depending upon the type of instrument, instruments 5 may undergo
different biocontamination reduction procedures (e.g., hand wash
vs. machine wash), or may be loaded into different racks or
containers associated with a biocontamination reduction apparatus.
After the first biocontamination reduction process is completed,
the unsorted instruments 5 are removed from the washer/disinfector,
and transported to sorting apparatus 50 (step 418) in trays 90 to
undergo a sorting process in advance of being transported to a
sterilizer (step 420), wherein instruments 5 undergo a second
biocontamination reduction process. It should be understood that
instruments 5 may be removed from the washer/disinfector by an
automated process (e.g., robotics), wherein instruments 5 are
dumped onto trays 90 for transport to sorting apparatus 50, or
directly placed onto sorting apparatus 50, without the use of trays
90. After processing by the sterilizer, instruments 5 may be
returned to the storage facility in trays 90.
[0037] It should be appreciated that steps 416, 418 and 420 may
take place offsite from the location of the medical procedure. For
example, "soiled" instruments 5 may be collected at a hospital, and
transported to a remote site for processing steps 416, 418 and 420.
Sterilized sets of instruments 5 are returned to the hospital when
required for a medical procedure.
[0038] As indicated above, instruments 5 may be transported to
sorting apparatus 50 on a tray 90. A plurality of trays 90 may be
loaded onto a mobile cart (not shown) to facilitate transportation
of instruments 5 between different locations. Instruments 5 are
unloaded from tray 90 onto transport members 54 of conveyer unit 52
(step 312). The unloading of tray 90 may be done manually (i.e., by
hand), or by use of an automation device, including, but not
limited to, one or more robotic arms (not shown). For instance, the
robotic arms may be programmed to grab, transport, and release
instruments 5. Robotic arm may use magnetics as a means for
grabbing instruments 5.
[0039] Empty trays 90 are preferably loaded onto second conveyer
unit 62, wherein they travel past a camera of second imaging system
35 that reads code 6 located oil trays 90. Code 6 is transmitted to
controller 58 of sorting apparatus 50. Controller 58, in turn,
relays code 6 to tracking system 10. Tracking system 10 accesses
database 22 to determine a "destination site" for the corresponding
tray 90. Tracking system 10 transmits data indicative of the
destination site to controller 58 of sorting apparatus 50.
Controller 58 controls conveyer unit 62 to convey tray 90 along a
travel path 64 to reach the specified destination site. Trays 90
are conveyed to destination sites in advance of any instruments 5
that are to be conveyed to the same destination site.
[0040] Conveyer unit 52 moves instruments 5 past a camera of
imaging system 30 that reads code 6 located on instruments 5 (step
314). Code 6 is transmitted to controller 58 of sorting apparatus
50. Controller 58, in turn, relays code 6 to tracking system 10.
Tracking system 10 accesses database 22 to determine a "destination
site" for the corresponding instrument 5 (step 316). For example, a
destination site may be medical instrument sets (e.g., major basic
surgery set). Tracking system 10 transmits data indicative of the
destination site to controller 58 of sorting apparatus 50.
Controller 58 controls conveyer unit 52 and transport members 54 to
deliver instruments 5 to the destination site along conveyor unit
52 (step 318). It should be appreciated that imaging system 30 may
also transmit a full image of instruments 5 for evaluation by
tracking system 10 for any irregularities. In this manner, visibly
damaged instruments 5 that need repair can be identified and
removed.
[0041] As indicated above, transport members 54 may include
cross-belts or tilt mechanisms to discharge articles from conveyer
unit 52 in a direction transverse to the travel direction of
transport member 54. In this manner, instruments 5 are deposited
onto trays 90. Alternatively, an automation device, including, but
not limited to, one or more robotic arms (not shown) may be used to
transfer instruments 5 from first conveyer unit 52 into trays 90.
Instruments 5 may also be transferred from first conveyer unit 52
to trays 90 by a manual process (i.e., by hand). Loaded trays 90
may then be loaded onto carts, and transported to a sterilizing
apparatus.
[0042] As discussed above, instruments 5 may be sorted by sorting
apparatus 50 into groups of like instruments. The sets of like
instruments are then transported to a sterilizing apparatus to
undergo a sterilization process. In accordance with another aspect
of the present invention, the sets of like instruments may be
loaded into a vending apparatus that operates in a manner similar
to a conventional snack or beverage vending machine. In this
regard, each set of like instruments is located in a separate
compartment, slot or chute in the vending apparatus. The vending
apparatus includes an input means for selecting a medical
instrument set, and dispenses appropriate instruments from each
compartment to assemble a specified medical instrument set. The
medical instrument set can then be removed from the vending
apparatus.
[0043] It should be understood that the sorting of instruments may
take place at times other than between the washing/disinfection and
sterilization processes. In this regard, instrument sorting may
take place anytime it is desirable to group the instruments by a
sort criteria.
[0044] Other modifications and alterations will occur to others
upon their reading and understanding of the specification. It is
intended that all such modifications and alterations be included
insofar as they come within the scope of the invention as claimed
or the equivalents thereof.
* * * * *